presentation lean manufacturing

Understanding Lean Manufacturing: A Kaizen Guide 

Lean Manufacturing represents an evolution in companies’ production practices and operational management. Originating from Japan, along with the Toyota Production System , this management philosophy has revolutionized manufacturing by offering an approach focused on maximizing value for the customer, eliminating anything that does not directly contribute to this objective. By emphasizing operational efficiency and continuous improvement , Lean Manufacturing seeks to optimize processes, reduce waste, and create high-quality products, responding promptly and flexibly to market changes. This article explores the essence of Lean Manufacturing and its evolution in the era of technology and digital transformation .

Introduction to Lean Manufacturing

Lean Manufacturing is a management approach derived from the Toyota Production System, devised in Japan after World War II. It aims to maximize value for the customer by eliminating waste , meaning it seeks to optimize processes by using fewer resources and focusing on what is essential to meet customer demands.

Definition and Significance 

This production model distinguishes itself by being a holistic and integrated approach, focusing on eliminating activities that do not add value to the final product. “Waste” can take various forms, including overproduction, transportation, overprocessing, and defects. Lean utilizes specific tools and techniques to identify and eliminate these wastes.

The significance of Lean Manufacturing transcends mere cost reduction or operational efficiency. It aims to foster a continuous improvement culture , where active participation of employees at all levels of the organization is crucial. This approach enhances the quality of products and processes and contributes to a better work environment.

Implementing Lean Manufacturing requires a mindset shift throughout the organization, from top management to line operators. A commitment to operational excellence places the customer at the center of all decisions. By embracing this direction, companies better meet customer needs and become more agile, flexible, and capable of responding to market changes more effectively.

The Core Principles of Lean Manufacturing        

Lean Manufacturing is a framework focused on optimizing production processes based on essential principles guiding organizations toward excellence. Let’s delve into the five fundamental principles of Lean Manufacturing and the process for identifying and eliminating waste.

5 Fundamental Principles in Lean    

The five pillars of Lean Manufacturing are fundamental principles that support this management philosophy, guiding organizations in implementing more efficient processes and eliminating waste. They form the foundation for value creation and continuous improvement within lean production. The five pillars are:

• Defining Value: The first step in Lean Manufacturing is understanding and defining value from the customer’s perspective. This means identifying what the customer values in the product or service so that efforts can be directed toward meeting those needs.
• Mapping the Value Chain: After defining value, the next step is to map the value stream, identifying all activities from raw material processing to the final product reaching the customer. The goal is determining which steps add value and which ones do not, laying the groundwork for waste elimination.
• Creating Flow: With the value stream mapped, the objective is to make products flow continuously without interruptions. This involves improving processes, reducing production batches, and eliminating waiting times, ensuring a more agile and efficient production.
• Establishing a Pull System: Instead of producing based on forecasts, Lean Manufacturing promotes demand-driven production, producing only what is needed, when requested, and in the required quantity. This reduces excess inventory and increases the ability to respond to market needs.
• Pursuing Perfection: The final principle is continuously searching for perfection, where continuous improvement integrates the company’s culture. This involves constantly optimizing processes, encouraging innovation, and involving employees in problem-solving.

Identifying and Eliminating Waste

Identifying and eliminating Muda (waste in Japanese) is central to the Lean philosophy. Waste is defined as any activity that consumes resources but does not create value for the customer. Traditionally, Muda is classified into seven types:

• Overproduction: Producing more than necessary or before it is needed.
• Idle Time: Waiting time due to poor synchronization, interruptions, or other reasons.
• Transportation: Unnecessary materials and products motion.
• Overprocessing: Steps that do not add value from the customer’s perspective.
• Stock: Products or materials sitting idle, whether raw materials, intermediate products, or finished goods.
• Motion and People: People movement.
• Defects and Errors: Producing defects or incorrect information, leading to rework or rejection.

Eliminating these wastes involves specific tools and techniques, such as Value Stream Analysis , Lean Line Design, Kanban, and Pull Planning, among many others. Processes will become more efficient, agile, and adaptable to customer needs, ensuring sustainability in production and the organization’s competitiveness in the market.

The Toyota Production System: A Lean Blueprint

The Toyota Production System (TPS) transformed the automotive industry and became the worldwide paradigm for lean production systems. Developed in Japan by the Toyota Motor Corporation shortly after World War II, the TPS was influenced by resource constraints and the needs of the Japanese market. Under the leadership of figures like Taiichi Ohno, Toyota sought to create a system that could quickly respond to changes in customer demand, minimize inventory, and ensure higher quality in its vehicles .

The Toyota Production System is sustained by two main pillars: Just-in-Time (JIT) and Jidoka. JIT aims to produce what is needed in the necessary quantity and at the right time. At the same time, Jidoka is an approach that focuses on immediately identifying and correcting problems on the production line.

Several other approaches are used within the TPS to promote efficiency and continuous improvement, such as Kaizen (Continuous Improvement), Kanban system (Visual Signaling), 5S (workplace organization methodology), and Heijunka (Production Leveling), among many others.

The Toyota Production System had a profound impact, inspiring the adoption of Lean and Lean Six Sigma practices across various sectors worldwide. TPS is not just a set of techniques but a management philosophy emphasizing leadership, people development, and a continuous improvement culture. The Lean model is still a reference for organizations seeking operational excellence and has also evolved – although its fundamental principles remain the same.

Implementing Lean Manufacturing

Implementing Lean Manufacturing primarily focuses on three major topics: essential stability, production flow, and internal logistics flow. These elements form the backbone of a lean production system, enabling companies to respond to the market with agility while maintaining quality and minimizing costs. Below, we dive into each topic.

Basic Stability

Primary stability is essential for an efficient and quality production system in Lean Manufacturing. This stability is built upon four crucial pillars:

• Labor: The importance of having a trained and skilled team capable of adapting to changes and driving continuous improvement.
• Machinery: To avoid interruptions and maintain production flow, ensure equipment/machines’ reliability and maintenance .
• Materials: Ensuring the materials needed for production are always available and meet the required quality standards, avoiding delays, and ensuring the final product’s quality.
• Methods: Implementing standardized work methods that ensure process consistency and efficiency, reducing variability and improving quality.

Combined, these elements support consistent and effective operations, which are fundamental for success in adopting Lean principles.

Production Flow

Flow in production is essential for maximizing productivity. To achieve continuous and efficient flow, several strategies and tools are implemented:

• Line Design and Layouts: Optimizing the production line layout to minimize unnecessary movements and facilitate materials and product flow.
• Workstation Design: Designing workstations ergonomically, minimizing movements, and enabling correct material supply at the point of use.
• Standard Work: Defining and implementing visual standards and operator training to ensure work consistency and efficiency.
• SMED (Single-Minute Exchange of Die): Methodology to significantly reduce tool changeover or setup time, contributing to flexibility and reducing idle times.
• Low-Cost Automation: Implementing simple, cost-effective automation solutions to improve efficiency without significant investments.

Internal Logistics Flow

Internal logistics in a Lean system aims to ensure an efficient and standardized supply of materials for production based on the following:

• Supermarkets: A supermarket is a ground-level storage area with visual management where consumption triggers replenishment.
• Mizusumashi (Logistics Train): A Mizusumashi is a logistics operator that follows a standardized circuit to supply components and remove finished products from the line, carrying all necessary information and production orders.
• Synchronization: Alignment between production and logistics , using Kanban or Junjo, to ensure suitable materials are available at the right time.
• Leveling: Even workload distribution to avoid production peaks, achieving a balanced workflow, usually using logistics box and leveling.
• Pull Planning: strategy based on actual demand planning, where production is triggered by the real need for the next step rather than relying on forecasts .

Lean and Technology: Evolving Together             

Technology is a powerful ally on the road to operational excellence in Lean Production. As we progress into the digital age, blending Lean principles and technological innovations opens new doors for process optimization, efficiency, and value creation.

Integrating ERP and Lean

Enterprise Resource Planning (ERP) systems are still key in incorporating technology into Lean principles. Integrating ERP solutions with Lean has allowed organizations to improve the information flow, automate processes, and facilitate data-driven decision-making. It enhances visibility across the entire value chain, from inventory management to customer satisfaction, ensuring that resources are used more effectively and aligned with waste reduction and continuous improvement objectives.

Lean in the Digital Transformation Era

Digital transformation provides an unprecedented opportunity for implementing Lean. When applied within Lean, tools like the Internet of Things (IoT), artificial intelligence (AI), and data analytics can revolutionize how organizations detect and eliminate waste.    

For example, IoT allows production process monitoring in real-time, facilitating swift identification of inefficiencies and improvement implementation. AI and data analytics provide predictive insights that assist in process optimization and proactive decision-making. These are just a few ways digital transformation can help Lean.

As organizations adapt to the digital environment, integrating Lean and technology becomes essential for achieving operational excellence. Even in an increasingly digital world, Lean Manufacturing principles remain as relevant as ever.

Lean Automation

Integrating automation into Lean Manufacturing is a powerful strategy. Unlike traditional automation, which often aims to increase production capacity without considering real needs, Lean automation focuses on the smart and selective application of technologies to meet specific continuous improvement goals and eliminate inefficiencies.

Lean automation is not simply about replacing human work with machines but identifying areas within processes where automation can bring quality, time, and cost benefits. This involves a structured assessment to ensure the implementation of robotics and autonomous systems is aligned with the defined strategy and does not introduce excess capacity or unnecessary operational complexity.

Conclusion            

Lean Manufacturing is more than just a set of production tools or techniques; it is a philosophy that guides how a company organizes and manages its operations. Its ultimate goal is to create maximum value with minimal waste, promoting continuous improvement and innovation culture. 

As we progress into the 21 st century, Lean Manufacturing continues to adapt and evolve, remaining a fundamental philosophy for organizations seeking operational excellence and sustainability. Looking to the future, Lean Manufacturing must continue to address emerging challenges, such as the growing demand for mass customization, the need for sustainable production practices, and the integration of increasingly complex global supply chains. However, quickly responding to these trends and leveraging Lean tools and principles will be crucial for long-term organizational success.

Lean is well-positioned to continue leading organizations toward operational excellence , focusing on sustainability and creating value for customers and stakeholders through its constant adaptation and integration with new technologies.

Still have some questions about Lean Manufacturing?             

What is the role of kaizen in lean manufacturing.

One of Lean Manufacturing’s foundations is Kaizen, which means continuous improvement. Kaizen is a management philosophy that involves the entire organization in improving processes, products, and services. It focuses on waste elimination and increasing value for the customer.

What is the difference between Lean Manufacturing and traditional manufacturing methods?

Lean Manufacturing focuses on continuous waste elimination and maximizing value for the customer. In other words, it typically uses fewer resources and delivers products of higher value for the customer than traditional production methods.

What is the impact of Lean Manufacturing on workforce productivity?

Lean Manufacturing can significantly increase workforce productivity by improving processes, reducing waste, and promoting a more organized and efficient work environment. This can also lead to an increase in employee satisfaction as they get involved in process improvement.

What are the environmental benefits of adopting Lean Manufacturing?

Adopting Lean Manufacturing can bring significant environmental benefits, including reducing resource consumption (energy, water, and raw materials), decreasing waste generation and emissions, and promoting sustainable and efficient processes. It can also create more sustainable products through Lean Product Development .

What are the financial implications of converting to a Lean Manufacturing system?

Transitioning to Lean Manufacturing typically leads to substantial cost savings due to waste reduction, improved operational efficiency, and better resource utilization. These changes not only increase profit margins but also enhance competitiveness in the market. They often result in increased sales due to improved service and product quality.

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Lean Manufacturing

Description  

In this Lean Manufacturing presentation, we explore the Lean philosophy, which is rooted in the Toyota Production System (TPS) . Lean aims to enhance customer value by optimizing p rocesses and eliminating waste, ultimately increasing productivity and value with fewer resources.

A key aspect of Lean is distinguishing between two types of activities: value-added (VA) and non-value-added (NVA) activities, assessed from the customer's perspective.

VA activities deliver value to products and services, such as answering customer queries or assembling parts, enhancing form, fit, or function, which customers are willing to pay for.

Conversely, NVA activities, like filing or waiting, add cost or time but do not contribute value and should be minimized or eliminated.

By addressing waste across the entire business process, organizations not only enhance the value of their offerings but also reduce costs, improve cash flow, and increase competitiveness, particularly in challenging times like a pandemic or downturn.

This Lean Manufacturing presentation equips managers and employees with a better understanding of Lean principles, waste elimination, and encourages active involvement in Lean implementation, promoting a culture of continuous improvement.

Note: This training package includes:

Lean Manufacturing PPT training presentation (PowerPoint format)

Lean poster (PDF format, in color and monochrome, printable in A3 size)

Eight Wastes of Lean p oster (PDF format, in color and monochrome, printable in A3 siz e)

Learning Objectives

Acquire knowledge on the key concepts and principles of Lean

Describe the Lean methods and tools for waste elimination and value creation

Describe the key roles in Lean deployment

Define the success factors for sustaining a Lean culture

1.  Introduction to Lean Manufacturing

The Case for Lean Manufacturing

History of the Toyota Production System

Toyota's Management Philosophy

What is Lean?

Five Principles of Lean

What Lean is Not

Lean Adoption in Various Environments

Impact of Lean Principles in Industry

Lean Applications in Manufacturing, Process and Service Industries

Traditional Thinking versus Lean Thinking

Traditional Culture vs. Lean Culture

Lean Manufacturing Framework

Benefits of Lean Manufacturing

2.  Key Concepts of Lean

Methods to Increase Productivity

What is Waste?

Work versus Waste

Value Defined

Cost Reduction Principle

Eight Wastes of Manufacturing

Examples of Value-added and Non-value Added Activities

Lean Thinking Philosophy

Lean Emphasis

3.  Lean Methods & Tools

Muda, Mura & Muri

Gemba Framework

5S Principles

Visual Management

Plant Layout

Cellular Layout

Total Productive Maintenance

Standard W ork

Heijunka (Leveling)

Value Stream Mapping

Pull Systems / Kanban

Continuous Flow

Quick Changeover / Set-up Reduction

Flexible Workforce

Quality at the Source

Poka-yoke (Mistake-proofing)

Andon 

Problem Solving

Small-Group Activities

Suggestion System

Hoshin Kanri

4.   Lean Roles

Lean Steering Committee

Lean Deployment Leader

Lean Champions

Lean Process Owner

Lean Team Leader

Lean Team Members

5.  Sustaining a Lean Culture

Challenges in Lean Manufacturing

Understanding Responses to Change

Sustaining a Lean Culture

Lessons from Other Adopters

You may also be interested in the following training presentations (sold separately):

Lean Thinking

Lean Office

Six Sigma Overview

5S Techniques

5S for the Office

Lean Manufacturing Tools

Lean manufacturing tools, techniques and philosophy | lean and related business improvement ideas.

5S Training Presentations

5s pptx and 5s pdf downloads.

If you want to learn all about 5S then the following 5S presentations in ppt (PowerPoint) format and PDF format are available to you for free download. Please note that these 5S Training presentation files are protected by copyright and are to be downloaded for your own personal use only.

• Any commercial use of these 5S presentations and the content therein is prohibited without prior permission. Requests for permission to use can be made through the contact page of http://leanmanufacturingtools.org/contact-page/
• These presentations are for personal use only and cannot be reproduced or circulated by anyone other than www.leanmanufacturingtools.org
• Content may be quoted or reproduced for private and educational assignments as long as a proper citation is given referring to leanmanufacturingtools.org
• The information within these presentations and website are for information purposes only and any action taken is at your own risk.

These lean manufacturing training presentations are organized so that you can tackle the ideas behind 5S one step at a time, for your own education or even to train others within your own organization. Breaking them up into bite sized chunks allows you to learn or teach 5S in manageable and understandable sections even if your available time is limited.

These presentations can be use in conjunction with the following pages here;

Running your own 5S program

How to approach 5S training

Run your own 5S training course in house

5S Training PowerPoint (pptx) Presentations;

Basic introduction to 5s presentations;.

What is 5S – Learn what is 5S.

Benefits of 5S – Learn the benefits of implementing 5S within your organization.

Presentations Detailing Each 5S Stage;

5S Seiri Sort – The first stage of implementing 5S.

5S Seiton Set in Order – The second stage of implementing 5S

5S Seiso Shine – The third stage of implementing 5S

5S Seiketsu Standardize – The forth stage of implementing 5S

5S Shitsuke Sustain – The fifth and final stage of 5S implementation

Lean 6S ppt Training Presentation;

6S – How does 6S differ from 5S and why?

Presentations Supporting Your 5S Training;

5S Red Tag – Learn how to use 5S Red Tags

Runners Repeaters Strangers – Learn how to apply RRS techniques when implementing 5S

Presentation Detailing How to Plan and Conduct Your 5S Implementation;

5S Program Implementation – Step by step guide to implementing 5S within your operations.

5S Training Exercise Presentation;

Training Exercise – 5S Paper exercise; a quick and simple training exercise designed for 5S which will demonstrate the simplicity and effectiveness of 5S.

5S Training PDF Files for Download;

All of the above 5S presentations are also available as 5S PDF files for download;

What is 5S Presentation

Benefits of 5S

5S Seiri or Sort – First stage of 5S

5S Seiton or Set In Order – Second stage of 5S

5S Seiso or Shine – Third stage of 5S

5S Seiketsu or Standardize – Forth stage of 5S

5S Shitsuke or Sustain – Final stage of 5S

5S Runners Repeaters and Strangers

Implementing 5S Program

5S Training Exercise

Should you require a personalized or editable version of these 5S PowerPoint presentations or 5S PDF files just contact the author through the contact page here; Leanmanufacturingtools.org contact page .

Suggestions for improvements or additions to the above 5S training presentations are welcomed.

Related posts:

• Lean Training, Coaching, and Presentations
• Free Lean Presentations
• 5S Training

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13 comments for “ 5s training presentations ”.

i want fully details of 5s

Hi K.P. Feel free to download any of the presentations and PDF files here to provide you with all of the info that you need on 5S.

PLEASE BRIEF ON 5S / 6S , LATEST VERSION. 6 SIGMA.

let me know more about it

5’S means house keeping in our Indian language . each and every letters are starting from “S” letters .so,called 1s,2s 3s,4s&5s . on japan language India language 1) seiri -short out 2)seiton -set in order 3) seiso -shine 4)seiketshu -standardization 5)sitsuke -sustain short out -1)material segregated require /un require.if, unwanted material will be put red tag and remove from our working area 2)if,required material then will be put yellow tag .3)if,not required but,well material then will be through to red zone area . Set in Order – required material will be keep by rack /cup board /shelves etc 3)shine identified material clean daily /weekly/yearly 4)standardization this 1s,2s,3s will be keep regularly. 5)sustain this work will be make habit.

How can I download the course?

Samer, Just click on the links to download each of the 5S presentations.

hi Earley i would like develop on these 5 s principles using my domain knowledge in the Oil and Gas upstream sector and would like to conduct workshops to our fraternity please confirm if you have any objection regards Damodaran M

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Lean Manufacturing (PowerPoint PPTX)

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Demystify Lean manufacturing. Improve your facility.

Put simply, Lean manufacturing seeks to improve production processes and increase efficiency. Lean manufacturing spans a variety of concepts and methods; therefore, getting started can intimidating and overwhelming. To help, we've created an easy-to-use presentation that introduces Lean ideas in a clear, accessible way. Lean can transform the way your company tackles production. Let us help get you started.

• Presents information in a simple, shareable format
• Includes explanations on 5S, Kaizen, 8 Wastes, and more
• Outlines how to implement Lean concepts into your facility
• Great for educating teams about Lean manufacturing

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Related Papers

TJPRC Publication

The purpose of this study is to examine how lean techniques are adopted by manufacturing firms in India and their impact on performance. This study gives the opportunity for the application of lean manufacturing techniques in a mix and low volume traditional manufacturing industries. VSM and associated tools are used to explore the opportunities to streamline the flow of products on the floor with a focus on reducing inventory and improving quality. This study has been carried out within the field of lean production. It has been aim to investigate and analyze how a company could implement the philosophy. Lean concept or lean manufacturing is a systematic methodology that identifies and eliminates all types of waste or non value added activities there are components that are considered “waste”. Lean concepts are purely about creating more value for customers by eliminating activities that are considered waste. Any activity or process that consumes resources, add cost or time without creating value becomes the target for elimination.

Jatin Parmar

— Use of the term “Lean”, in a business or manufacturing environment describe a philosophy that incorporates a collection of tools and techniques into the business process to optimize time, human resources, assets and productivity, while improving the quality level of products and services to their customers. Productivity is also the impact of peoples working together. Machines are merely an extended way of collective imagination and energy. Lean manufacturing is one of the most used method for continuous improvement of business. Organization management philosophy focuses on the reduction of wastage to improvement of overall customer value. Keep in mind that Lean applies to the entire organization.

Abstract: Lean Manufacturing Implementation: An Approach To Reduce Production Cost . Opportunities to improve production processes and reduce production cost through the implementation of lean manufacturing in small medium garment manufacturing are presented in this research. This research shows that there is a possibility of decrease in production cost and increase in return on sales. Lean manufacturing implementation can eliminate waste in the production process. This is a set of techniques for identification and elimination of waste gathered from The Ford Production, Statistical Process Control and other techniques. Improvement of quality could be carried out while time and cost of production are being reduced. Abstrak: Implementasi Lean Manufacturing: Suatu Pendekatan Biaya Produksi. Kesempatan untuk memperbaiki proses produksi melalui implementasi lean manufacturing di sebuah usaha produksi garmen kecil dan menengah, dipresentasikan dalam artikel ini. Riset ini menunjukkan ba...

IJERA Journal

In manufacturing industries lean manufacturing is a broadly accepted philosophy. There are more requirements of research and studies. To investigate the needs, techniques, benefits of lean manufacturing and approaches for implementation Lean manufacturing is a leading manufacturing paradigm has applied in many economy sectors, where we have to reduce manufacturing cost, improving product quality, reducing cost of poor quality, and quick to respond and " first to market to customer needs are critical to competitiveness and success. Lean methods and principle focus on the continuous improvement and engages employees reducing the intensity of materials, time, and capital necessary for meeting a customer's needs. Successful implementation of lean manufacturing is very important to increase quality and waste reduction. By implementation of lean manufacturing there are various benefits such as waste elimination, reduction in reworking, financial benefits, lead time reduction and lower inventory levels.

ravi purohit

As a period is moving assembling enterprises are moving to the spots where work charges are less yet after setup likewise the assembling cost won't increment with time in light of the fact that there will be climb in labor charges, crude material charge, transport cost additionally deterioration and so forth these all outcomes in higher assembling cost per unit. likewise to maintain in this aggressive market producer can't expand the selling cost so this outcome in lessening of the edge (Profit ) so as to manage the profit level the main way is chip away at assembling cost diminishment and this can be accomplished by lean assembling. Lean assembling is a system where wastages and non-esteem exercises get lessened by executing lean tools and making process wind up plainly lean so lean assembling is turning into a requirement for assembling businesses. This paper incorporates data about lean assembling, their advantages, execution process, and lean tools.

Niranjan Hugar

Applying Lean manufacturing philosophy is one of the most important concepts that help enterprises to gain competitive advantage in the world market. Lean manufacturing or lean manufacturing is a manufacturing practice that emphasizes on the use of resources for work which add value for the end customer. The purpose of this paper is to give an overview of the lean principles, tools and benefits of lean concepts in manufacturing industries. Lean manufacturing is plethora of principles that focus on cost reduction by identifying and eliminating non value added activities. The fiercely globalized and competitive markets of 21st century demand for increasing high variety of products at lowest possible costs, lesser lead time and high quality. This changing market scenario calls for a new manufacturing that will enable us to compete in this global competitive market. This research addresses the application of lean manufacturing concepts to the continuous production/process sector with a ...

Springer Texts in Business and Economics

Alexander Tsigkas

Inventory is one of the eight deadly wastes in Lean. It is caused by overproduction (producing more than is immediately needed) but in turn it causes several other wastes. How does excess inventory manifest itself? I.e. Extra space, Extra people, waste conveyance, extra costs. Inventory management in lean is built around the same principles that govern most lean activity: create a simple set of tools that can be used directly in the workplace that will help surface problems so that they can be addressed. Inventory management is thus quite different in lean, starting with the view of inventory as a waste rather than an asset. From a practical point of view, what this means is that inventory reduction is built into the fabric of the system , just like it is for any other waste. Because of this, they are typically no special efforts or programs aimed at reducing excess inventory. Reducing inventory is a part of everyday work life.In this paper we will cover two important topics for the...

— Applying Lean manufacturing philosophy is one of the most important concepts that help enterprises to gain competitive advantage in the world market. Lean manufacturing or lean manufacturing is a manufacturing practice that emphasizes on the use of resources for work which add value for the end customer. The purpose of this paper is to give an overview of the lean principles, tools and benefits of lean concepts in manufacturing industries. Lean manufacturing is plethora of principles that focus on cost reduction by identifying and eliminating non value added activities. The fiercely globalized and competitive markets of 21st century demand for increasing high variety of products at lowest possible costs, lesser lead time and high quality. This changing market scenario calls for a new manufacturing that will enable us to compete in this global competitive market. This research addresses the application of lean manufacturing concepts to the continuous production/process sector with ...

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Lean Manufacturing - PowerPoint PPT Presentation

Lean Manufacturing

Lean manufacturing – powerpoint ppt presentation.

• Below is a picture of the Toyota Production System House.
• The 5S System
• Lean is the fundamental way that many of the worlds best companies do business.
• The two main focuses of Lean are Continuous Improvement, and Respect for People.
• Continuous improvement, also called kaizen, defines much of Lean.
• The true meaning of kaizen is in
• Creating an atmosphere of continuous learning.
• Not only accepting, but actually embracing change.
• Most companies currently practicing lean, are merely using lean tools or techniques, but lack the systemic continuous improvement, continuity and organizational learning of true lean companies.
• There are seven major types of non-value-adding waste in business or manufacturing processes
• OverproductionProducing items for which there are no orders.
• WaitingWorkers watching an automated machine or waiting for the next processing step, tool, supply, or part.
• Principle 1
• Base your management decisions on a long-term philosophy, even at the expense of short-term financial goals.
• Lean advocates the use of cards, empty bins, or empty carts called kanban.
• The visual indicator in the grocery store is the empty shelf, like an empty bin or cart in a kanban system.
• Principle 5
• Build a Culture of Stopping to Fix Problems, to get Quality Right the First Time.
• Quality for the customer drives your value proposition.
• Use all modern QA methods available.
• The value of Lean lies not in computers and machines, but in supporting people, processes and values.
• In lean companies, new technology should be proven through direct experimentation with the involvement of a broad cross-section of people.
• Principle 14
• Become a learning organization through relentless reflection (hansei) and continuous improvement (kaizen).
• AndonA lighted warning system to be used when a defect or problem is encountered.
• GembaGo to the place where the work is being done to see for yourself.
• Download Lean Manufacturing PowerPoint presentationat ReadySetPresent.com305 slides include 24 slides on the foundation of lean, including 2 points on kaizen, 2 points on keiretsu, 4 areas of lean, the 4 Ps, and 5 steps in the process of lean 20 slides on eliminating waste, including 7 major types of non-value-adding waste and 5 points on one-piece-flow 10 slides on the lean house model 14 principles of lean, including 6 slide on long-term philosophy, 14 slides on continuous process flow, 14 slides on using pull systems, 16 slides on heijunka, 23 slides on production philosophy, 14 slides on standardized tasks, 24 slides on visual controls, 11 slides on the use of reliable technology, 18 slides on developing leaders who value your organizations culture, 21 slides on developing employees who value your organizations culture, 8 slides on challenging and helping partners and suppliers, 8 slides on genchi genbutsu,16 slides on decision-making, 23 slides on becoming a learning organization 6 slides on japanese words related to lean, 17 action steps, how-tos and much more.
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Introduction to Lean Manufacturing

Oct 14, 2013

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Introduction to Lean Manufacturing. Lean Manufacturing Definition. Lean has been defined in many different ways.

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Lean Manufacturing Definition Lean has been defined in many different ways. “A systematic approach to identifying and eliminating waste(non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.” By The MEP Lean Network Intro-To-Lean

History Timeline for Lean Manufacturing Intro-To-Lean

Lean manufacturing is a philosophy In 1990 James Womack, Daniel T. Jones, and Daniel Roos wrote a book called “The Machine That Changed the World: The Story of Lean Production-- Toyota's Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry” In this book, Womack introduced the Toyota Production System to American. What was new was a phrase– "Lean Manufacturing." Intro-To-Lean

How to Increase Profit? Intro-To-Lean

Muda (Waste) Taiichi Ohno (1912-1990), the Toyota executive who was the most ferocious foe of waste human history has produced, identified the first seven types of muda in manufacturing system: • Storage • Transportation • Waiting • Motion • Process • Defects • Over-productionMuda is everywhere. Intro-To-Lean

Lean Overview Intro-To-Lean

Lean Manufacturing Tools • 5S • Value Stream Mapping • Standardized Work • Load Leveling • Kaizen • Kanban • Visual Workplace • Quick Changeover • Andon • Poka-yoke • One-piece flow • Cellular Manufacturing Intro-To-Lean

Production Planning System (Push System) Intro-To-Lean

Push or Pull? A push system Intro-To-Lean

Push or Pull? A pull system Intro-To-Lean

Kanban Operation Intro-To-Lean

Raw materials inventory Semi-finished parts Semi-finished parts Station 2 Material handler Order receiving Station 1 8 4 11 3 14 11 3 10 4 1 11 11 13 13 7 7 7 7 6 2 5 9 12 8 WK WK WK PK PK PK Station 3 RM RM RM Finished goods Intro-To-Lean

Current State Map of A Case Study Example Intro-To-Lean

At which stations, are parts withdrawn? At which stations, are parts scheduled? Future State Map Intro-To-Lean

Which to Choose — MRP (ERP), or Kanban? Where MRP (ERP) works best: • MRP is by its very nature a forward-looking system. • MRP can be very effective in an environment with a great deal of variability. • MRP is recognized an engine to drive an integrated enterprise-wide information system. Purchasing and logistics activities were similarly being integrated with fundamental internal materials management principles into an enterprise-wide approach. Intro-To-Lean

MRP or Lean Manufacturing? Where MRP is not as effective. • MRP is a predictive system. It does not reflect to customer’s demand (easy to get overproduction). • A company takes MRP suggestions and acts on them without too much review is very risky. • MRP won’t fully support the cost-cutting. • MRP needs lots of data for production management. • MRP generates high overhead. • MRP builds high work-in-process. • MRP’s lead times are fixed. • MRP creates potential quality hazard. Intro-To-Lean

Which to Choose — MRP (ERP), or Kanban? Where Kanban works best. Kanban is a very reactive system. Very little is planned ahead. Instead, Kanban causes replacement of material used in a totally reactive mode. Kanban works best in a highly stable and predictable environment. Where it is not as effective. Kanban can quickly fail in a highly volatile environment because of the reactive nature of the system. Volatility in customer demand, processing problems, and extensive changes in product designs make it very difficult for a Kanban system to work effectively. Intro-To-Lean

Which to Choose — MRP (ERP), or Kanban? Kanban and MRP Combination The combination of these two systems is becoming quite common. An MRP system is used for advanced planning, including long lead-time purchased materials, adding resources, and implementing product design changes. Once the MRP has the materials and resources “lined up,” however, Kanban is used as an execution system, bringing with the characteristics of rapid response to customer order and reduced inventory levels throughout the process. Hybrid Systems Intro-To-Lean

The Objections to Lean • How should you deal with these objections to lean? • “It is very hard to deal with raw material suppliers if we fully depend on customer order.” • “It takes too much discipline.” • “It takes too long to implement.” • “My process is too complex; I have to deal with too many uncontrollable variables, like late supplier shipments, sick people, etc.” • “My process requires a large batch size.” • “It doesn’t make sense in my industry.” • “It’s unclear to me how lean will work with my MRP system.” Intro-To-Lean

Lean and Green The environmental impacts due to production and waste generation have made its way into every day society. Consumers are becoming more environmentally conscious. With the Earth’s limited resources, companies are more conscious of their carbon footprint, and there has been a movement to create more environmentally friendly decisions. Green engineering is the systems-level approach to product and process design where environmental attributes are treated as primary objectives or opportunities rather than simple constraints. Intro-To-Lean

lean manufacturing is a link to green engineering Lean manufacturing is the business model and collection of tactical methods that emphasize eliminating non-value- added activities (waste) while delivering quality products at lowest cost with greater efficiency. In conjunction, six goals of green engineering are: Select low environmental impact materials. Avoid toxic or hazardous materials. Choose cleaner production processes. Maximize energy and water efficiencies. Design for waste minimization. Design for recyclability and reuse of material. Intro-To-Lean

lean manufacturing is a link to green engineering Population grows Wastes increase Fossil fuels are diminishing and there is nothing replenishing them. Consumers are becoming more aware of the environment and prefer environmentally friendly companies. Being lean and green is so important now to reduce the consumption of natural resources and the CO2 concentration in the Earth’s atmosphere. The only real difference between lean and green manufacturing is that green actually designs the product or process with the environment as a constraint while lean creates a process with the view of the environment as a valuable resource and not a constraint. Intro-To-Lean

Key Steps in Transforminga Company to the Lean Approach • Establish a steering team—conduct strategic planning session • Train the steering team and the model line team in the disciplines of lean • Perform PQR (product-quantity-routing) analysis • Identify value streams—select a value stream • Calculate model line takt time • Value stream map the model line—assemble current state map • Balance the line—assign standard work • Establish standard WIP (inventory levels) • Test the system (virtual cell)—document results • Setup reduction event Intro-To-Lean

Key Steps in Transforminga Company to the Lean Approach • Conduct 5S event—apply TPM techniques • Establish visual signals—reduce paperwork • Explore alternative flow patterns • Develop block layout • Develop detailed layout • Execute move • Select next value stream and repeat Gary Conner, President of Lean Enterprise Training, Newport, OR, Road Map to Lean for the Smaller Shop, Society of Manufacturing Engineers, Lean Manufacturing 2007, Supplement to Manufacturing Engineering, 2007. pp. 27-29. Intro-To-Lean

References • Society of Manufacturing Engineers, Lean Manufacturing 2007, Supplement to Manufacturing Engineering, 2007. • Society of Manufacturing Engineers, Lean Manufacturing 2008, Supplement to Manufacturing Engineering, 2008. • Garrett Brown and Dara O’Rourke, “LeanManufacturingComestoChina: A Case Study of its Impact on Workplace Health and Safety,” International Journal of Occupational and Environmental Health (IJOEH), 13(3), JUL/SEP 2007. • Challenges in Applying Lean Manufacturing in China, McKinsey Quarterly, 2006 Special Edition available at Jackson Library. Friday, October 12, 2007 | Posted by Simone Yu in International Intro-To-Lean

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The 2408 update to SAP S/4HANA Cloud Public Edition brings the latest enhancements to our intelligent ERP solution, designed to help businesses run efficiently and effectively.

As a leader in the SaaS and cloud-enabled midsize business ERP applications market, as named by IDC , we are committed to delivering continuous value to our customers. Let’s dive in and explore the exciting new enhancements of SAP S/4HANA Cloud Public Edition 2408 update.

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